Methods and apparatus for applying protective films

Abstract

A method of applying a polymeric anti-chip coating to an automobile body surface such as a rocker panel using a hydraulic extrusion die to form and emit a non-atomized ribbon of material onto adhering contact with said rocker panel. The ribbon can be varied in width by robotically turning the die about the flow axis and proportionally changing the ratio of material flow to speed of die movement to maintain ribbon thickness.

What is claimed is: 
     
         1 . A method of adheringly applying a ribbon of a polymer-based film as an anti-chip coating to the rocker panel of an automobile body comprising the steps of:
 a. providing a fluidic polymeric solution to an inlet of an applicator configured to emit a non-atomized ribbon of said solution;   b. causing said solution to flow through said applicator to produce said ribbon from an outlet;   c. positioning the applicator near but not in contact with said rocker panel during production of said ribbon; and   d. moving the die along and relative to the rocker panel surface to cause the ribbon to adheringly contact the rocker panel surface.   
     
     
         2 . The method defined in  claim 1  where the solution includes one or more of polyvinyl chloride, polyurethane, epoxy, and acrylic resins. 
     
     
         3 . The method defined in  claim 2  wherein the solution includes an organic solvent. 
     
     
         4 . The method as defined in  claim 1  wherein the speed of movement between the die and rocker panel approximates the flow rate of the ribbon from the die. 
     
     
         5 . The method as defined in  claim 1  wherein the rocker panel is primed before the anti-chip ribbon is applied. 
     
     
         6 . The process of  claim 1  wherein the steps of applying the coating are carried out without masking the rocker panel. 
     
     
         7 . A method of creating a uniform anti-chip film of polymeric material on a body panel surface including the steps of:
 a. supplying a homogeneous fluidic solution of a polymer in a solvent to an inlet of an application die having an inner flow path from said inlet to an outlet having configuration capable of producing a non-atomized ribbon of fluidic material;   b. emitting said ribbon continuously from said outlet;   c. placing the applicator at known distance relative to a rocker panel of an automobile with the direction of fluidic emission substantially normal to the rocker panel surface so that substantially the entirety of the emitted ribbon adheringly contacts the panel surface; and   d. causing the applicator to move along and relative to the panel surface.   
     
     
         8 . The method defined in  claim 7  wherein the die is rotated about the axis of material flow to change the width of the pattern during the movement step. 
     
     
         9 . The method defined in  claim 7  wherein the rocker panel surface is painted after the application of the pattern but before the applied anti-chip material is dry. 
     
     
         10 . The method defined in  claim 10  wherein the method is carried out without masking off the rocker panel. 
     
     
         11 . A method of finishing the rocker panels of a vehicle comprising the steps of:
 a. priming a rocker panel surface;   b. robotically applying a non-atomized ribbon of a polymeric emulsion containing one or more of PVC, polyurethane, epoxy, or an acrylic resin onto the primed surface by extrusion; and thereafter,   c. painting over the applied ribbon.   
     
     
         12 . The method defined in  claim 11  wherein the ribbon has a thickness of about 300 to 350 mm.